SYSTEMS AND METHODS FOR PROVIDING NON-CORROSIVE SURFACES

BACKGROUND OF THE INVENTION
1. Field of the Invention

The present invention relates to providing non-corrosive surfaces. In particular, the present invention relates to systems and methods for providing non-corrosive, non-slip surfaces and surface overlays for use in exterior environments. At least some implementations include systems and methods for providing non-corrosive surfaces directly to failed concrete and/or to metal structures for walking traffic.

2. Background and Related Art

Concrete consists of a mixture of cement and water. As cement hardens and dries, excess mixing water in the cement evaporates. This causes shrinkage, which tends to result in cracks and deterioration in the cement.

Hardened concrete is also susceptible to corrosion, cracking, and deterioration. This may be caused by corrosion of reinforcing steel and other embedded metals in the concrete, as well as by normal freezing and melting cycles. Excess water in the concrete will freeze at temperatures below 32° F., causing expansion of around 9% in all directions. When the cold temperatures rise to above freezing, the ice melts and runs deeper into the cement structure which allows more water into the cracks from melting ice and snow. The cycle repeats again and again with greater effect until the surrounding concrete fractures and fails.

Salt and other chemical ice melts applied to the surface of the concrete can exacerbate the problem by also causing corrosion within the layers of the concrete. Salt and ice melts also unnaturally affect the freezing and melting process, which can cause additional issues.

Thus, while techniques currently exist for melting accumulated snow and ice on concrete, challenges still exist, including damage and corrosion on concrete surfaces. Accordingly, it would be an improvement in the art to augment or even replace current techniques with other techniques.

SUMMARY OF THE INVENTION

The present invention relates to providing non-corrosive, non-slip surfaces and surface overlays for use in exterior environments.

Implementation of the present invention takes place in association with preserving concrete floors and structures. In some implementations, a polymer material is applied directly to the concrete surface, filling any damage or corrosion in the concrete and providing a protective layer on the concrete. In a further implementation, a texture and/or granular material (such as sand or other material) is included in the polymer material to provide a non-slick surface. In a further implementation, a system for providing a non-corrosive surface includes a concrete surface, a metal substrate coupled to the concrete surface, and a non-corrosive coating applied to the metal substrate or metal structure. In some implementations, the non-corrosive coating includes a polymer, such as a chemically inert polymer having EPDM rubber and a granular additive, crystalline additive, glass fibers, or other additive. In some implementations, a heating element or system is coupled to the metal substrate.

While the methods and processes of the present invention have proven to be particularly useful in the area of providing non-corrosive surfaces for exterior concrete structures such as stairs, those skilled in the art can appreciate that the methods and processes can be used in a variety of different applications and in a variety of different areas of manufacture to yield non-corrosive, non-slip surfaces for various exterior surfaces including sidewalks, porches, patios, driveways, parking lots, landscaping, swimming pools, and other structures or surfaces.

These and other features and advantages of the present invention will be set forth or will become more fully apparent in the description that follows and in the appended claims. The features and advantages may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. Furthermore, the features and advantages of the invention may be learned by the practice of the invention or will be obvious from the description, as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the manner in which the above recited and other features and advantages of the present invention are obtained, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that the drawings depict only typical embodiments of the present invention and are not, therefore, to be considered as limiting the scope of the invention, the present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 illustrates a representative cement staircase that provides a suitable operating environment for use of at least some embodiments of the present invention;

FIG. 2 illustrates a representative cement porch and staircase that provides a suitable operating environment for use of at least some embodiments of the present invention;

FIG. 3 illustrates another representative cement surface that provides a suitable operating environment for use of at least some embodiments of the present invention;

FIG. 4 illustrates a representative non-corrosive composition used in connection with a representative cement staircase in accordance with certain embodiments of the present invention;

FIG. 5 is a perspective view of a non-corrosive composition used in connection with a cement structure in accordance with some embodiments;

FIG. 6 is a top view of a surface in accordance with certain embodiments of the present invention;

FIG. 7 is a perspective view of a surface treated with a non-corrosive composition in accordance with some embodiments;

FIG. 8 is a perspective view of a sidewalk ramp in accordance with some embodiments;

FIG. 9 is a perspective view of a porch and staircase in accordance with some embodiments;

FIG. 10 is a perspective view of a sidewalk, porch, and stairs in accordance with certain embodiments of the present invention;

FIG. 11 is a perspective view of a porch and staircase in accordance with certain embodiments;

FIG. 12 is a perspective view of a porch surface in accordance with some embodiments;

FIG. 13 is a rear perspective view of a metal substrate formed into a sidewalk surface in accordance with some embodiments;

FIG. 14 is front perspective view of the metal substrate of FIG. 13;

FIG. 15 is a front perspective view of the metal substrate of FIG. 13 having a non-corrosive coating applied thereto in accordance with certain embodiments;

FIG. 16 is a rear perspective view of a representative metal substrate formed into a staircase in accordance with some embodiments;

FIG. 17 is a side perspective view of the staircase of FIG. 16;

FIG. 18 is a front perspective view of the staircase of FIG. 16;

FIG. 19 is a perspective view of a representative staircase and landing in accordance with some embodiments of the present invention;

FIG. 20 is a plan diagram of one embodiment of a system in accordance with the present invention;

FIG. 21 is a perspective side view of a representative embodiment of a system in accordance with the present invention;

FIG. 22 is a perspective view of a representative embodiment of a system including a porch, landing surface, and stairs;

FIG. 23 is a perspective view of one embodiment of stairs and a lateral support structure;

FIG. 24 is a perspective view of stairs between two sidewalls in accordance with some embodiments;

FIG. 25 is a bottom view of stairs coupled to a sidewall in accordance with certain embodiments;

FIG. 26 is a perspective view of representative embodiment of a system having stairs and a banister; and

FIG. 27 is a side perspective view of the representative embodiment of FIG. 26, depicting an exposed sidewall.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to systems and methods for providing non-corrosive surfaces and surface overlays. Embodiments of the present invention include non-corrosive, non-slip surfaces and/or surface overlays to preserve and protect underlying concrete surfaces.

Embodiments of the present invention take place in association with preserving concrete floors and structures. In some embodiments, a polymer material is applied to the concrete surface, filling any damage or corrosion in the concrete and providing a protective layer on the concrete. In a further embodiment, a texture and/or granular material (such as sand or other material) is included in the polymer material to provide a non-slick surface. In a further embodiments, a system for providing a non-corrosive surface includes a concrete surface, a metal substrate coupled to the concrete surface, and a non-corrosive coating applied to the metal substrate. In some embodiments, the non-corrosive coating includes a polymer, such as a chemically inert polymer having EPDM rubber and a granular additive, crystalline additive, glass fibers, or other additive. In certain embodiments, a heating element or system is coupled to the metal substrate. FIGS. 1-3 illustrate various examples of concrete structures 100 having surfaces that have corroded and deteriorated over time. As shown in FIGS. 1-2, some existing concrete structures 100 include a staircase and/or landing or porch area. As shown, concrete structure 100 includes various concrete surfaces 106 that have corroded and deteriorated over time. Corrosion 102 can be visible, for example, on the landing area 112, tread surfaces 108, risers 110, and side wall 114 of a stair structure 100, as well as on a surrounding concrete floor surface 106. Referring now to FIG. 3, concrete surface 106 includes a cement pad, curb, or other surface. In some embodiments, concrete surface 106 includes a liner for a saltwater pool or other structure, for example. Corrosion 102 includes cracks or gaps 104 that extend in various directions across the surface 106 and/or edges 116 of the concrete structure 100.

In some embodiments, a system for providing a non-corrosive surface may be applied to such corroded concrete surfaces to protect and preserve the underlying concrete and to create a finished aesthetic surface that appears new.

Referring now to FIGS. 4-5, in some embodiments, a system 400 for providing a non-corrosive surface includes a non-corrosive material or coating 404 that is applied directly to concrete surface 106. As shown, in some embodiments, the non-corrosive material or coating 404 provides a patch to repair an area of corrosion 102 on the surface 106. In other embodiments, the system 400 for providing a non-corrosive surface includes a non-corrosive material or coating 404 that is applied to a metal substrate, such as aluminum, steel, copper, iron, or an alloy thereof. In one embodiment, the metal substrate includes an atmospheric corrosion resistant steel. In some embodiments, the metal substrate includes one or more segments or is monolithically formed as a single unit. In these and other embodiments, the metal substrate can be overlaid onto a concrete surface 106 as discussed in more detail with reference to FIGS. 8-12 below, or can be used independently.

In these and other embodiments, the non-corrosive material or coating 404 includes a chemically inert polymer and a granular or crystalline additive. In one embodiment, the non-corrosive material or coating 404 includes about fifty percent (50%) polymer and about fifty percent (50%) additive by volume. In other embodiments, the polymer occupies more than 50% by volume of the non-corrosive material or coating 404.

Advantageously, in some embodiments, the non-corrosive material or coating 404 is inert to salt as well as to all forms of ice melting chemicals. In some embodiments, the non-corrosive material or coating 404 is inert to natural elements of the earth. Thus, in some embodiments, once the system 400 for providing a non-corrosive surface is installed, salt and ice melting chemicals can be applied with no additional damage resulting to the underlying concrete surface 106 or to the overlay.

In some embodiments, the polymer and resulting non-corrosive material or coating 404 exhibits excellent heat, ozone/weathering, aging and abrasion resistance. In some embodiments, the polymer and resulting non-corrosive material or coating 404 further exhibits excellent electrical insulation, compression set, and low temperature properties. For example, in some embodiments, the polymer is stable in environments with temperatures between about −45° F. and above 170° F. In certain embodiments, the polymer includes ethylene propylene diene monomer (“EPDM”) or liquid rubber, thermoplastic polyolefin (“TPO”), tar, thermoplastic vulcanizates (TPVs), or the like.

Some embodiments of the polymer are very flexible and stretchable to facilitate application of the non-corrosive material or coating 404 to surfaces having surface imperfections. In one embodiment, the polymer includes EPDM rubber and is stretchable of up to five hundred percent (500%) by mass.

In these and other embodiments, the non-corrosive material or coating 404 includes an adhesion and bonding strength relative to concrete surfaces such as sidewalks, porches, stairs, curbs, and the like. In some embodiments, the non-corrosive material or coating 404 includes adhesion and bonding strength relative to metal surfaces such as aluminum, steel, copper, and alloys thereof. In these and other embodiments, the non-corrosive material or coating 404 is long-lasting in all weather conditions.

In certain embodiments, the non-corrosive material or coating 404 seals a surface such that it is rendered impenetrable to moisture. For example, as depicted in FIGS. 4-5, some embodiments of the non-corrosive material or coating 404 is applied to seal a surface 106 and even fill in cracks or gaps 104 between adjacent surface areas. In some embodiments, one or more fillers, such as foam, dirt, wood, rock, gravel, plaster of paris, or the like, are deposited to fill surface voids before the non-corrosive material or coating 404 is applied.

Referring now to FIGS. 6-7, some embodiments of the non-corrosive material or coating 404 further includes a granular or crystalline additive. In some embodiments, inclusion of the additive provides a change in property, such as increasing the stiffness of the non-corrosive material or coating 404 and/or providing a non-slick surface in the non-corrosive material or coating 404. In certain embodiments, the additive facilitates application of the non-corrosive material or coating 404 to existing surfaces 106. In some embodiments, the additive increases the co-efficient of traction of the non-corrosive material or coating 404 to facilitate safety where the non-corrosive material or coating 404 is designed to be walked on or traveled over. In some embodiments, the additive includes a natural sand, blow sand, silica sand, or other suitable granular or crystalline material.

In some embodiments, the crystalline additive improves the appearance of the surface 106 after the non-corrosive material or coating 404 is applied. In certain embodiments, the additive and/or the polymer includes one or more colors to vary and/or improve the appearance of the non-corrosive material or coating 404 and the surface 106 to which it is applied.

In some embodiments, the non-corrosive material or coating 404 is applied to the surface 106 with a trowel, roller, screed, paint brush, sprayer, or other suitable tool. In some embodiments, the non-corrosive material or coating 404 is sprayed on to a surface 106. In some embodiments, the tool used to apply the non-corrosive material or coating 404 includes one or more features configured to form a texture 600 or pattern in the non-corrosive material or coating 404. In these and other embodiments, various techniques for using the application tool create the texture 600 or pattern in the non-corrosive material or coating 404. In some embodiments, the texture 600 or pattern provides a non-slip surface. In some embodiments, the texture 600 or pattern disguises corrosion 102 or other imperfections in the surface 106, and/or improve the appearance, strength, and/or life of the surface 106.

Referring now to FIGS. 8-12, in some embodiments, a system 400 for providing a non-corrosive surface includes a concrete surface 106, a metal substrate or surface overlay 800 coupled to the concrete surface 106, and a non-corrosive material or coating 404 applied to the surface overlay 800. As discussed above, in some embodiments, the surface overlay 800 is formed as multiple segments or can be monolithically formed as a single unit.

As shown in FIG. 8, in one embodiment, the concrete surface 106 includes a sidewalk ramp. In some embodiments, one or more surface overlays 800 are coupled to the concrete surface 106 via one or more fasteners, adhesives, and/or couplers. In some embodiments, the surface overlays 800 are aligned such that an outside edge of one surface overlay 800 contacts an outside edge of an adjacent surface overlay 800. In some embodiments, adjacent surface overlays 800 is coupled to one another surface overlay. In other embodiments, adjacent surface overlays 800 are spaced apart from one another by a defined distance, or in any other desired configuration or manner.

Referring now to FIGS. 9-11, in some embodiments, the concrete surface 106 includes a concrete staircase or other concrete structure. In some embodiments, the concrete surface 106 includes one or more of a landing area 112, a tread surface 108, a riser surface 110, a side wall surface 114, a floor surface 118, or other suitable concrete structure or surface 106. In some embodiments, the system 400 for providing a non-corrosive surface includes surface overlays 800 configured to overlay each of the concrete surfaces 106. Adjacent surface overlays 800 are coupled together via one or more fasteners such as screws, nails, rivets, or the like. In some embodiments, an adhesive such as very high bond (“VHB”) tape is used to couple adjacent surface overlays 800 together. In some embodiments, the surface overlays 800 are coupled to the concrete surfaces 106 by way of one or more fastening mechanisms known to those in the art.

In some embodiments, the non-corrosive material or coating 404 is applied to the surface overlay 800 prior to positioning the surface overlay 800 on the concrete surface 106. In other embodiments, the non-corrosive material or coating 404 is applied to the surface overlay 800 after it is coupled to the concrete surface 106.

Referring now to FIG. 10, in some embodiments of a system 400 for providing a non-corrosive surface, one or more fillers 402 are deposited into cracks and gaps 104 between adjacent concrete surfaces 106 before the non-corrosive material or coating 404 is applied to seal the space. In other embodiments, the non-corrosive material or coating 404 is deposited into the cracks and gaps 104 to act as filler as well as a sealant. In certain embodiments, the non-corrosive material or coating 404 fills in cracks and gaps 104 in failed concrete up to a half inch wide.

Referring now to FIG. 11, in some embodiments, the surface overlay 800 is formed to include a size and shape substantially matching the underlying concrete surface 106. In other embodiments, the surface overlay 800 includes a size and shape larger than the underlying concrete surface 106 to create a desired aesthetic appearance.

Certain embodiments include one or more heating elements coupled to the surface overlay 800 to prevent freezing, melt ice and snow, and improve surface traction. In some embodiments, the heating element includes, for example, an electric, radiant, or hydronic heating element coupled to or disposed beneath or adjacent to the surface overlay 800. In some embodiments, the heating element is coupled to a power source. In some embodiments, the power source is a solar power source.

In one embodiment, for example, one or more heating elements are coupled to or disposed beneath each surface overlay 800 segment. In other embodiments, a series or array of heating elements are coupled to or disposed beneath each surface overlay 800. In some embodiments, the heating elements are coupled to or disposed at predetermined distances between surface overlays 800 or are positioned adjacent to one or more surface overlays 800.

In some embodiments, the heating element is configured to maintain the temperature of the surface overlay 800 above freezing (above 32° F.). For example, in some embodiments, the heating element is configured to maintain the surface overlay 800 above freezing. In some embodiments, the heating element is configured to maintain the surface overlay up to about 10° F. above freezing. In some embodiments, the heating element is configured to maintain the surface overlay more than 10° F. above freezing.

Referring now to FIGS. 12-15, some embodiments of a system 400 for providing a non-corrosive surface include a flat concrete area such as a porch, landing area 112, or floor surface. In other embodiments, the system 400 for providing a non-corrosive surface includes a flat concrete area such as a sidewalk, ramp, driveway, or parking area. In such embodiments, the system 400 for providing a non-corrosive surface includes high compression strength sufficient to support the weight of automobiles and other vehicles.

In some embodiments, the metal substrate or surface overlay 800 includes multiple segments 800a, 800b coupled together. In one embodiment, as shown in FIGS. 13-15, one segment 800a is aligned with an adjacent segment 800b along its horizontal edge. In some embodiments, the system 400 for providing a non-corrosive surface includes a frame 802 or rails to facilitate segment 800a, 800b alignment. In some embodiments, each segment 800a, 800b is coupled to the frame 802 and/or to an adjacent segment 800a, 800b via one or more fasteners 1400a, 1400b. In some embodiments, fasteners 1400 include, for example, one or more screws, nails, rivets, seams, crimps, welds, or the like. In certain embodiments, a segment 800a is attached to the frame 802 and/or to an adjacent segment 800b via an adhesive.

Referring now to FIG. 15, in some embodiments, multiple segments 800a, 800b are attached to the frame 802 prior to application of the non-corrosive material or coating 404. In this manner, in some embodiments, the non-corrosive material or coating 404 is applied to extend over and/or seal a gap 804 between adjacent segments 800a, 800b. Similarly, the non-corrosive material or coating 404 is applied to extend over exposed portions of fasteners 1400a, 1400b used to couple the segments 800a, 800b to each other and/or to the frame 802.

Referring now to FIGS. 16-19, in some embodiments, a system 400 for providing a non-corrosive surface includes providing a metal substrate structure 1600 that may be used independently from a concrete substructure. In one embodiment, as shown in FIG. 16 for example, the substrate structure 1600 includes aluminum or another suitable metal that may be bent or otherwise formed to include a set of stairs and a landing area 112. As shown, the substrate structure 1600 includes one or more attachment surfaces 1610 such as a top edge 1602 and side edges 1604 extending from a rear periphery of the substrate structure 1600.

In some embodiments, the top edge 1602 extends in a transverse direction relative to the landing area 112. Similarly, one or more of the side edges 1604 extends in a transverse direction relative to the side walls 114 of the substrate structure 1600. An adhesive and/or fastener is applied to the top edge 1602 and/or side edges 1604 to secure the substrate structure 1600 to an adjacent structure. As illustrated in FIG. 19, in some embodiments, the attachment surfaces 1610 are disposed to correspond to an adjacent wall of the existing structure such that the substrate structure 1600 is secured to the existing structure.

With reference to FIGS. 17-18, in some embodiments, a base edge 1608 extends in a transverse direction from a front periphery of the substrate structure 1600 to facilitate securing the substrate structure 1600 to a ground level. In some embodiments, one or more lateral edges 1606 extend in a transverse direction from a base of the side wall 114 to further secure the substrate structure 1600 to the ground level.

Referring now to FIGS. 20-22, some embodiments of the substrate structure 1600 include multiple surfaces 106 that interlock or are otherwise coupled together. For example, as shown in the diagram 2000 of FIG. 20, some embodiments of the substrate structure 1600 include interlocking steps 2006 having a tread surface 108 formed to extend in a transverse direction into a riser surface 110.

In some embodiments, the interlocking steps 2006a, 2006b is formed from aluminum, steel, Corten steel, copper, or an alloy thereof. Some embodiments of the interlocking steps 2006a, 2006b include multiple tread surfaces 108 formed to extend into riser surfaces 110 on each lateral side. In some embodiments, the riser surface 110 extends substantially perpendicularly relative to the tread surface 108. As illustrated in FIGS. 20-21, in some embodiments, a base edge 2002 of one riser surface 110 includes an interlocking lip 2004 configured to engage a base edge 2002 of the other riser surface 110. In some embodiments, the interlocking lip 2004 extends at an angle of between 30° and 60° relative to the base edge 2002. In one embodiment, the interlocking lip 2004 extends at a 45° angle relative to the base edge 2002. In this manner, some embodiments provide a series of interlocking steps 2006a, 2006b where an interlocking lip 2004 of one step 2006a engages a base edge 2002 of another step 2006b.

In some embodiments of a system 400 for providing a non-corrosive surface, the series of interlocking steps 2006a, 2006b are implemented as an overlay to protect an existing concrete structure 100. In other embodiments, the series of interlocking steps 2006a, 2006b are installed independently without an underlying concrete substructure. As shown in FIG. 22, in one embodiment, the system 400 for providing a non-corrosive surface is installed for independent use by securing the series of interlocking steps 2006a, 2006b against an existing structure, such as a house. In some embodiments, this can stabilize the system 400 without requiring a base structure. Some embodiments of the series of interlocking steps 2006a, 2006b includes fasteners 1400 and/or adhesives to further secure a first interlocking step 2006a to a second interlocking step 2006b.

Referring now to FIGS. 23-27, in some embodiments, the system 400 utilizes a foundation structure 2300 to further stabilize a substrate structure 1600 such as a series of interlocking steps 2006a, 2006b for independent use. In this manner, in certain embodiments, the series of interlocking steps 2006a, 2006b are implemented without a base substructure. As shown, in some embodiments, the foundation structure 2300 includes one or more sidewalls 2302a, 2302b secured to the interlocking steps 2006. In one embodiment, the foundation structure 2300 is coupled to one or more attachment surfaces 1610 extending from the interlocking steps 2006a, 2006b.

In some embodiments, the foundation structure 2300 further includes one or more angle supports 2304 disposed beneath the interlocking steps 2006a, 2006b. The angle supports 2304 conform to a size and shape of a portion of each step 2006 to provide stability thereto. As shown in FIG. 25, in some embodiments, the angle supports 2304 are secured to the foundation structure 2300 via one or more attachment devices of mechanisms such as bolts, screws, nails, rivets, or the like.

Referring to FIGS. 26-27, in some embodiments, a method for providing a non-corrosive surface in accordance with some embodiments of the invention include providing a substrate structure 1600 including a metal such as aluminum, steel, copper, iron, and/or alloys thereof. In some embodiments, the substrate structure 1600 is overlaid onto an existing cement or concrete surface 106, such as stairs, a porch area, a landing area, a floor, a pool, pool stairs, a hot tub, a wall, a parking lot, or other structure. In other embodiments, the substrate structure 1600 is used independently or overlaid onto a non-cement structure such as a vehicle or equipment surface. In some embodiments, the method includes providing one or more heating elements disposed adjacent to the substrate structure 1600 to maintain the substrate structure 1600 at temperatures above freezing.

In some embodiments, the substrate structure 1600 is coupled to the existing structure and a non-corrosive material or coating 404 is applied thereto. In some embodiments, a filler 402 is used to fill voids in the existing concrete surface 106 prior to applying the non-corrosive material and/or coating 404. In other embodiments, the non-corrosive material or coating 404 is used as the filler 402.

In some embodiments, the non-corrosive material or coating 404 includes a chemically inert polymer and a additive, such as a granular, crystalline, or other additive. In some embodiments, the chemically inert polymer includes EPDM rubber and the additive includes sand. In some embodiments, the non-corrosive material or coating 404 includes about 10-60% by volume of the chemically inert polymer. Applying the non-corrosive material or coating 404 to the substrate structure 1600 includes applying a texture 600 or pattern to the non-corrosive material or coating 404 to provide a non-slip surface.

Thus, as discussed herein, embodiments of the present invention provides a non-corrosive, non-slip surface. The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

SYSTEMS AND METHODS FOR PROVIDING NON-CORROSIVE SURFACES

Information

Publication Number

Date Filed

Date Published

Inventors

CPC

International Classifications

Abstract

Description

Claims

RELATED APPLICATIONS

Provisional Applications (1)